JP2000263578A - Method for molding foamed resin composite molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mold a foamed resin composite molded object wherein uniformly foamed resin particles are strongly fused mutually and a foamed resin body is strongly fused to a front material and a back material. SOLUTION: A formed resin composite molded object 1 consisting of a foamed resin body 1 and the front material 11 and back material 13 integrally bonded to the upper and back surfaces thereof is molded by using a mold 2. The back material 13 having a plurality of vent holes 131 for supplying and discharging steam is arranged on the bottom surface 211 of the molding chamber 21 of the mold 2 and the surface material 12 is arranged to the upper surface 213 of the molding chamber 21. Foamed resin particles are charged in the foaming space 22 formed by both materials 12, 13 and steam 41 is supplied to the foaming space 12 from one or more vent holes 131 and discharged from the remaining vent holes 131 to heat and foam the foamed resin particles.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a foamed resin composite molded article comprising a foamed resin body, a front surface material and a back surface material.

[0002]

2. Description of the Related Art Conventionally, as a method for molding a foamed resin composite molded article comprising a foamed resin body, a front surface material and a back surface material, Japanese Patent Laid-Open Publication No.
Japanese Patent Application Laid-Open No. 238,761. The above-mentioned conventional molding method is a method of molding a foamed resin composite molded body including a panel frame having at least one open surface and a foamed resin body. That is, the foaming space in the panel frame is filled with the foamed resin particles while pressure is maintained from the surroundings, and then steam is supplied from the open portion to heat and foam the foamed resin particles. The resin molded body is integrally formed.

[0003]

However, the above-mentioned conventional method has the following problems. That is, in the case of a foamed resin composite molded article composed of a foamed resin body, a surface material, and a back surface material, only the small face is opened, and steam is supplied from the small face. At this time, since the distance between the fore-edge surface and the fore-edge surface on the opposite side is long, the supplied steam does not sufficiently flow to the vicinity of the fore-edge surface on the opposite side, and the exhaust cannot be sufficiently performed.

[0004] As a result, the foamed resin particles may not be heated and foamed uniformly in the foamed space between the front surface material and the back surface material. For this reason, there is a possibility that the foamed resin particles do not firmly fuse with each other, or the foamed resin particles and the surface material and the back surface material.

The present invention has been made in view of the above-mentioned conventional problems, and the foamed resin particles are uniformly foamed, and the foamed resin particles and the foamed resin body are firmly fused with the surface material and the back surface material. An object of the present invention is to provide a method of molding a foamed resin composite molded article attached thereto and a foamed resin composite molded article obtained by the method.

[0006]

According to the first aspect of the present invention, there is provided a foamed resin body,
A method of molding a foamed resin composite molded body composed of a front surface material and a back surface material integrally joined to the front and back surfaces of the foamed resin body using a mold, wherein the molding method is as described above. On the bottom side of the molding chamber of the mold, a backing material with a plurality of ventilation holes for steam supply and exhaust is arranged, while on the top side of the molding chamber, a surface material is arranged and formed by both. A preparatory step of introducing foamed resin particles into the foaming space, and supplying steam to the foaming space from one or more of the vents, and exhausting air from the remaining vents, And a heat foam molding step of heating foam molding of the resin particles.

It is most remarkable in the present invention that the backing material has a plurality of air holes, from one or a plurality of the air holes, steam is supplied to the foaming space, and the other air holes are provided. After that, exhaust is performed to heat and expand the foamed resin particles. As the steam, for example, steam at 105 ° C to 165 ° C is used.

Next, the function and effect of the present invention will be described.
Since the back material has a plurality of air holes, in the heating foam molding step, steam can be supplied from the air holes to the foaming space and exhausted. That is, in the heating foam molding step, steam can be supplied from the thickness direction of the foamed resin composite molded article. Therefore, the steam supplied to the foaming space portion easily flows to the vicinity of the surface material of the foamed resin composite molded article, and the foamed resin particles in the foaming space portion can be uniformly heated and foamed. Further, since the back material is provided with a vent hole, the fore edge and the vent hole,
The distance between the vents is reduced, and steam can be supplied and exhausted efficiently.

Therefore, the foamed resin particles and the foamed resin particles and the surface material and the back surface material can be firmly fused. In addition, since the gas is exhausted from the bottom surface, the moisture of the steam agglomerated in the molding chamber can be efficiently discharged to the outside of the molding chamber. Therefore, moisture in the obtained foamed resin composite molded article can be reduced.

As described above, according to the present invention, a foamed resin composite molded article in which foamed resin particles are uniformly foamed and the foamed resin particles and the foamed resin body and the surface material and the back surface material are firmly fused together. A molding method can be provided.

Next, as in the second aspect of the present invention, the mold has a chamber disposed at a part or the whole of the periphery of the molding chamber, and at least one of the chambers is provided in the molding chamber. The chamber arranged on the bottom is partitioned into a plurality of compartments, each compartment has a communication hole communicating with the molding chamber, and each compartment is connected to a steam supply pipe and an exhaust pipe. In the heating foam molding step, steam is supplied from one or more predetermined first compartments of the plurality of compartments to the foaming space in the molding chamber through the communication holes and the vent holes provided in the back material. The first heating step of discharging gas in the space of the foaming space from the second compartment other than the first compartment through the communication hole and the ventilation hole, and the second heating step, contrary to the first heating step. From the branch office Supplying air, whereas from the first compartment preferably has a second heating step for discharging space gas.

[0012] In the above molding method, the first heating step includes:
Steam is supplied from the first compartment to the molding chamber, and exhaust is performed from the second compartment. Therefore, depending on the arrangement of the reinforcing material in the foamed resin composite molded article and the like, it is determined which of the first compartment and the second compartment to perform the function of the steam supply or exhaust, and the supply and exhaust of the steam are performed. By performing the above, steam can be efficiently supplied to the entire foaming space.

[0013] In the second heating step, the direction of steam supply and the direction of exhaust are reversed from those in the first heating step. Therefore, the foamed resin particles in the vicinity of the first compartment in the foaming space are prevented from foaming and fusing earlier than the foamed resin particles in the vicinity of the second compartment, thereby preventing the foaming of the foamed resin particles from becoming uneven. be able to. Therefore, the foamed resin is sufficiently fused, and a foamed resin composite molded article having higher strength can be obtained.

Next, it is preferable that the first compartment and the second compartment are alternately arranged. Thus, in the heating step, the vapor passes through the foaming space more evenly, so that the foamed resin particles in the foaming space can be uniformly heated and fused. Therefore, a foamed resin molded article having higher strength can be formed.

Next, as in the fourth aspect of the present invention, it is preferable that the compartment for discharging the gas in the space in the heating and foaming step is suctioned under reduced pressure. Thereby, the gas in the space of the foaming space can be more efficiently exhausted, and the heat fusion of the foamed resin particles can be performed more efficiently. Further, it is possible to prevent an extra gas in the space from remaining inside the foamed resin composite molded article.

Next, as in the invention as set forth in claim 5, a foamed resin composite comprising a foamed resin body, and a front surface material and a back surface material integrally joined to the front and back surfaces of the foamed resin body. There is a molded article, wherein the back surface material has a vent for supplying and exhausting steam at the time of molding the foamed resin composite article.

The foamed resin composite molded article has a vent on the back surface for supplying and exhausting steam. Conventionally, when a foamed resin body and a front surface material and a back surface material are integrally formed, steam can be supplied only from a small surface of the foamed resin composite molded body. On the other hand, in the case of the foamed resin composite molded body, since steam can be supplied from the ventilation holes of the back surface material, as described in the description of the first aspect of the present invention, the foamed resin particles in the foamed space portion are formed. Can be uniformly foamed.

[0018] Thus, no gap is formed between the foamed resin body and the surface material and the back surface material, and a foamed resin composite molded article excellent in airtightness and heat insulation can be easily obtained. Therefore, it is possible to easily obtain a foamed resin composite molded article in which the foamed resin particles and the foamed resin particles are firmly fused with the front surface material and the back surface material.

As described above, according to the present invention, the foamed resin particles are uniformly foamed, and the foamed resin particles are firmly fused together, and the foamed resin particles and the surface material and the back surface material are tightly bonded to each other. The present invention can provide a foamed resin composite molded article having excellent heat resistance and heat insulation properties.

Next, a reinforcing material can be provided between the front surface material and the back surface material. Also in this case, the steam flows sufficiently to the foaming space. Therefore, the foamed resin particles are uniformly foamed, and the foamed resin particles are firmly fused with each other, and the foamed resin particles and the surface material and the back surface material, and a foamed resin composite molded article having higher strength can be obtained. .

Next, as in the invention according to claim 7, the reinforcing material can be provided over the entire thickness of the foamed resin body. Also in this case, similarly to the invention according to claim 6, the foamed resin particles are uniformly foamed, and the foamed resin particles are firmly fused with each other, and the foamed resin particles and the front surface material and the back surface material are further fused. A foamed resin composite molded article having high strength can be obtained.

Next, as in the invention as set forth in claim 8, the reinforcing material can be disposed at the small face and the center in the width direction on the entire circumference of the foamed resin composite molded article. . Also in this case, similarly to the invention according to claim 6, the foamed resin particles are uniformly foamed, and the foamed resin particles are firmly fused with each other, and the foamed resin particles and the front surface material and the back surface material are further fused. A foamed resin composite molded article having high strength can be obtained.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1 A method for forming a foamed resin composite molded article according to an embodiment of the present invention will be described with reference to FIGS. The molding method of this example is a foamed resin composite molded article 1 (FIG. 3) composed of a foamed resin body 11 and a surface material 12 and a backside material 13 integrally joined to the front and back surfaces of the foamed resin body 11. ) Using a mold 2 (FIG. 1A).

The molding method has the following preparation step and heating foam molding step. In the above preparation process, FIG.
As shown in (A), the bottom surface 2 of the molding chamber 21 of the mold 2 is formed.
On the 11th side, there are a plurality of ventilation holes 1 for supplying and exhausting steam.
The backing material 13 having the base material 31 is arranged, while the surface material 12 is arranged on the upper surface 213 side of the molding chamber 21, and foamed resin particles are put into the foaming space 22 formed by the both. In the heating foam molding step, as shown in FIG. 1 (A), steam 41 is supplied from one or a plurality of ventilation holes 131 to the foaming space 22, and the remaining ventilation holes 1 are supplied.
Air is exhausted from 31 to heat and expand the foamed resin particles.

The mold 2 has chambers 3 and 30 disposed around the molding chamber 21 as shown in FIGS. The chambers 3 arranged on the bottom surface 211 and the side surface 212 of the molding chamber 21 among the chambers 3 and 30 are partitioned into a plurality of sub-chambers 31. on the other hand,
The chamber 30 disposed on the upper surface 213 of the molding chamber 21
Is not divided into branches. Each compartment 31 has a communication hole 319 communicating with the molding chamber 21 (FIG. 5), and each compartment 31 is connected to a steam supply pipe 51 and an exhaust pipe 52 (FIG. 10).

The heating and foaming step includes the following first heating step and second heating step. In the first heating step, as shown in FIGS. 1, 5 and 2A, a plurality of predetermined first compartments 311 of the plurality of compartments 31 are connected to the communication holes 319 and the back surface material 13. Vent holes 13 provided
1 to the foaming space 22 in the molding chamber 21 through the steam 4
Supply 1 On the other hand, at the same time, the gas 42 in the space of the foaming space 22 is exhausted from the second compartment 312 other than the first compartment through the communication hole 319 and the ventilation hole 131.

In discharging the gas 42 in the space, the second compartment 312 is suctioned under reduced pressure. Further, in the second heating step, as shown in FIG. 2B, contrary to the first heating step, steam 41 is supplied from the second compartment 312, while steam is supplied from the first compartment 311. The space gas 42 is exhausted. The first and second compartments 311 and 312
Are alternately arranged as shown in FIG.

Next, the foamed resin composite molded article 1 molded according to this embodiment will be described with reference to FIGS. The foamed resin composite molded article 1 includes a foamed resin body 11 and a surface material 1 integrally joined to the front and back surfaces of the foamed resin body 11.
2 and the back material 13. The back material 13 is shown in FIG.
As shown in FIG. 2B, a vent hole 131 for supplying and exhausting steam during molding of the foamed resin composite molded article 1 is provided.

The foamed resin composite molded article 1 has a reinforcing member 14 disposed between the front surface member 12 and the back surface member 13.
The reinforcing member 14 is disposed at the center in the width direction of the foamed resin composite molded article 1 and at one of the small faces 15 over substantially half of the entire thickness of the foamed resin body 11 (FIG. 3A,
(B), FIG. 4). In addition, as shown in FIG. 4B, the foamed resin composite molded article 1 of this example has a phased shape in the width direction, and is used as a building board or the like to be used in the width direction. .

Next, the operation and effect of this embodiment will be described. Since the back material 13 has a plurality of ventilation holes 131,
In the heating foam molding step, steam 41 can be supplied from the ventilation hole 131 to the foaming space 22 to exhaust the gas (FIG. 1A).

That is, in the heating foam molding step, the steam 41 can be supplied from the thickness direction of the foamed resin composite molded article 1. Therefore, the steam 41 supplied to the foaming space 22 is applied to the surface material 1 of the foamed resin composite molded article 1.
2, the foamed resin particles in the foaming space 22 can be uniformly heated and foamed. Furthermore, since the back material 13 is provided with the ventilation holes 131,
And the distance between the ventilation holes 131 and the ventilation holes 131 and the ventilation holes 131 is shortened, so that the steam can be efficiently supplied and exhausted. Therefore, the foamed resin particles and the foamed resin particles and the surface material 12 and the back surface material 13 can be firmly fused.

In the above-mentioned molding method, the first heating step includes:
The steam 41 is supplied from the first compartment 311 to the molding chamber 21 and, in parallel with this, the gas 42 in the space is exhausted from the second compartment 312 (FIG. 2A). Therefore, depending on the arrangement of the reinforcing members 14 in the foamed resin composite molded article 1, etc.,
First compartment 31 for exerting the function of steam supply or exhaust
It is possible to efficiently supply the steam 41 to the entire foaming space 22 by deciding which of the first and second compartments 312 should be the compartment 31 and supplying and exhausting the steam 41.

In the second heating step, steam 41
The direction of supply and the direction of exhaust are reversed in the first heating step (FIG. 2).
(B)). Therefore, the foamed resin particles in the vicinity of the first compartment 311 in the foaming space 22 are separated by the second compartment 312.
It is possible to reliably prevent the foaming resin particles from being foamed and fused earlier than the foamed resin particles in the vicinity, and the foaming of the foamed resin particles from becoming uneven. Therefore, the foamed resin is sufficiently fused, and the foamed resin composite molded article 1 having higher strength can be obtained.

The first compartment 311 and the second compartment 31
2 are alternately arranged, so that the vapor 41 more uniformly passes through the foaming space 22 in the heating step, so that the foamed resin particles in the foaming space 22 can be uniformly heated and fused. Therefore, the foamed resin composite molded article 1 having higher strength can be molded.

In exhausting the gas 42 in the space, the first compartment 311 or the second compartment 312 is suctioned under reduced pressure. Therefore, the gas 42 in the space of the foaming space 22 can be more efficiently exhausted, and the heat fusion of the foamed resin particles can be performed more efficiently. Further, it is possible to prevent the extra space gas 42 from remaining inside the foamed resin composite molded article 1.

As described above, according to this embodiment, the foamed resin composite molded article in which the foamed resin particles are uniformly foamed and the foamed resin particles are firmly fused together, and the foamed resin body and the surface material and the back surface material are firmly fused. A molding method can be obtained.

Embodiment 2 As shown in FIG. 6, this embodiment is an example of a foamed resin composite molded article 101 having no reinforcing material. That is, the foamed resin composite molded body 101 includes a foamed resin body 11 and the foamed resin body 11.
The front surface material 12 and the back surface material 13 are integrally joined to the front side surface and the back side surface. Other configurations are the same as those of the first embodiment.

In the case of this embodiment, when the foamed resin composite molded body 101 is formed, the ventilation holes 131,
In addition, steam can be supplied to the foaming space from the small opening surface 15 and the gas in the space can be exhausted. Thus, the same operation and effect as those of the first embodiment can be obtained.

Embodiment 3 As shown in FIG.
This is an example in which a reinforcing material 14 is provided over the entire thickness of the foamed resin body 11 at the center in the width direction and integrally molded. Other configurations are the same as those of the first embodiment.

Also in the case of this embodiment, similar to the second embodiment,
Vent hole 1 in back material 13 of foamed resin composite molded article 102
The steam can be supplied to the foaming space from the small face 31 and the four sides 15 and the gas in the space can be exhausted.
Thus, the same operation and effect as those of the first embodiment can be obtained.

The ventilation holes 131 are provided in the reinforcing member 1.
It is preferable that a large number be formed around the periphery of No. 4. This gives
In the vicinity of the reinforcing member 14, the vent hole 1
The steam 41 flows smoothly from the vent hole 131 to the small face 15. Therefore, the foamed resin particles around the reinforcing member 14 can be more efficiently heated and foamed, and can be firmly heated and fused to the reinforcing member 14.

Fourth Embodiment As shown in FIG.
This is an example in which a reinforcing member 14 is provided over the entire thickness of the foamed resin body 11 on two opposing small edge surfaces 15 at the center in the width direction and at both ends in the width direction, and is integrally formed. Others
This is the same as the first embodiment.

In the case of the present embodiment, steam is supplied to the foaming space from the ventilation holes 131 of the backing material 13 and the small end surfaces 150 at both ends in the longitudinal direction in the foamed resin composite molded article 103, and the gas in the space is supplied. Can be exhausted. Thus, the same operation and effect as those of the first embodiment can be obtained.

Embodiment 5 In this embodiment, as shown in FIG.
Of the foamed resin body 11 around the center in the width direction of the
This is an example in which the reinforcing member 14 is provided over the entire thickness of the resin and formed integrally. Other configurations are the same as those of the first embodiment.

In the case of this embodiment, steam can be supplied to the foaming space from the ventilation hole 131 of the back material 13 of the foamed resin composite molded body 104, and gas in the space can be exhausted. Thus, the same operation and effect as those of the first embodiment can be obtained.

Example 1 In this example, a method for molding the foamed resin composite molded article 1 of Example 1 using the mold 2 and the molding machine 20 (FIG. 10) will be specifically described. As shown in FIG. 10, the molding machine 20 employs a vertical up and down opening and closing type. Mold clamping is hydraulic cylinder 24
Then, the flat mold 28 is tightened and fixed with the side lock pins 27. The opening and closing mechanisms of the valve 59 were all manually operated.

Next, the mold 2 will be described with reference to FIGS.
0 and FIG. The mold 2 shown in FIG.
This is a mold for foaming resin molding comprising a flat mold 28 and a concave mold 29 shown in FIG. The flat mold 28 was provided with a chamber 30. Further, as shown in FIG. 10, the flat mold 28 is provided with a steam supply / discharge line 301 and a water-cooling / air-cooling pipe (not shown) from the outside.

The concave mold 29 was provided with a chamber 3. The chamber 3 is integrally provided on the bottom surface 211 and the side surface 212 of the molding chamber 21. The chamber 3 is provided with a partition wall 35 orthogonal to the bottom surface 211 of the molding chamber 21 and divided into six compartments 31 (FIG. 1).
(A)). The bottom surface 211 and the side surface 212 of the molding chamber 21
The chamber 3 is separated from the chamber 3 by an inside wall provided with a large number of slit-shaped communication holes 319 as shown in FIG.

As shown in FIG. 10, the molding machine 20 is provided with a first pipe 53 connecting three first compartments 311,
A second pipe 54 connecting the three second compartments 312 and a water / air cooling line (not shown) were provided. Chamber 3 at the bottom
Are provided at a pitch of 466 mm. In FIG. 10, reference numeral 58 denotes a drain discharge pipe for discharging the steam drain, and reference numeral 201 denotes a tie rod for smoothly moving the flat type 28 up and down.

A filling gun 25 for filling the foaming resin particles into the molding chamber 21 and a release pin 26 for releasing the foamed resin composite molded article from the molding chamber 21 are provided.
Are arranged on the bottom surface 211 as shown in FIG. Mold 2
The dimensions of the molding chamber 21 were 910 × 2800 mm.

As shown in FIG. 1A, the flat mold 28 preferably has one chamber 30 and has no communication hole on the molding chamber 21 side. If the chamber 30 has a communication hole, the steam drain may adhere to or contain water on the surface material 12, which may cause a reduction in performance or increase in weight.

Next, the front surface member 12, the back surface member 13, and the reinforcing member 14 will be described. As the surface material 12, a metal plate, a resin plate, a wooden plate, a concrete plate, a tile, or the like can be used. When the adhesive property between the foamed resin body 11 and the surface material 12 and the back material 13 is poor, an adhesive is applied to the surface material 12 and the back material 13 in advance to form an adhesive layer, so that the adhesive after molding is formed. Improve power. Further, by providing a groove or a protrusion having an inverse taper on the bonding surface of the front surface member 12 and the back surface member 13, the adhesion to the foamed resin body 11 can be further strengthened.

As the adhesive layer, an organic solvent-based or water-dispersed adhesive that is applied by brushing or the like and dried can be used. Epoxy, urethane, vinyl acetate, recycled rubber, and synthetic rubber adhesives can be used as the organic solvent adhesive. Acrylic, vinyl acetate, acrylic, SBR and the like can be used as the water-dispersed adhesive. The coating ^{amount, 40g / m 2 ~300g / m} 2 is preferred.

Further, as the reinforcing member 14, a reinforcing member made of metal, resin, wood or the like can be used. In order to improve the adhesive strength between the reinforcing member 14 and the foamed resin body 11, it is preferable to apply an adhesive in advance similarly to the front surface member 12 and the back surface member 13. Vent hole 131 of back material 13
May be a circle or a square, and examples thereof include a shape and an arrangement example as shown in FIG. The area of the vent hole 131 is preferably 7 cm ² to 50 cm ^2. Further, the pitch of the ventilation holes 131 is 10 to 30 c in the longitudinal direction.
m, 40 to 90 cm in the width direction.

Next, the expanded resin particles will be described. As the foamed resin particles, thermoplastic foamed resin particles can be used. As the type of the foamed resin particles, for example, polystyrene resin particles, polypropylene resin particles, and polyethylene resin particles can be used. Among them, polystyrene resin particles are particularly preferable. The expansion ratio of the expanded resin particles is preferably 30 to 80 times.

Next, FIGS. 1, 2 and 1 show the molding method.
0 and FIG. FIG. 10 shows the molding machine 2
0 shows a side sectional view, and FIG. 2 illustrates the flow of steam 41 in the foaming space 22. In FIG. 10, the flow of steam and exhaust gas in the pipe in the first heating step is indicated by a solid line arrow, and the flow in the second heating step is indicated by a dotted arrow.

First, the preparation process will be described. In the vertical molding machine 20 of FIG. 10, the flat mold 28 is opened with the cylinder 24 on the upper side, and the back material 13 provided with the ventilation holes 131 is arranged on the bottom surface 211 of the concave mold 29. Next, the reinforcing members 14 are arranged as shown in FIGS.
Next, after disposing the surface material 12, the flat mold 28 is tightened and fixed with the side lock pins 27. Next, foam resin particles are filled from the filling gun 25 attached to the bottom surface 211 of the concave mold 29. In addition, the foamed resin particles are mixed with the air holes 1.
Even if the filling is performed from 31, an opening for filling may be newly provided in the back material 13 (not shown), and the filling may be performed from the opening.

Next, the heating foam molding step will be described.
Each of the sub-chambers 3 obtained by partitioning the chamber 3 of the concave mold 29 into six chambers
A first heating step of performing vacuum suction from the second compartment 312 other than the first compartment 311 while supplying the steam 41 to a predetermined first compartment 311 of FIG. 1 (FIG. 2A). Next, a second heating step in which the steam supply side and the vacuum suction side of the first heating step are exchanged is performed (FIG. 2B).

That is, in the first heating step, while the steam 41 is supplied through the steam supply pipe 51 and the first pipe 53 to the three first compartments 311 in the chamber 3 of the concave mold 12, one of the three Vacuum suction of the molding chamber gas 42 from the second compartment 312 through the second pipe 54 and the exhaust pipe 52 (solid arrows in FIG. 10).

In the second heating step, the steam supply side and the vacuum suction side in the first heating step are exchanged, and the second compartment 31
2, the steam 41 from the steam supply pipe 51 and the second pipe 54
And exhaust is performed from the first compartment 311 through the first pipe 53 and the exhaust pipe 52 (dotted arrow in FIG. 10).

After the first heating step, the chamber 3
Taking a vacuum suction process from all the compartments 31 of
The internal pressure of the chamber 3 may be increased to a reduced pressure, and then the process may proceed to the second heating step. After the first heating step and the second heating step, the first and second compartments 311 and 31
2 Steam 41 is supplied from all the compartments 31.

As shown in FIG. 2, each of the compartments 31 has a structure in which first compartments 311 and second compartments 312 are sequentially arranged alternately on the same plane. And
In the first heating step, steam 41 flows into the molding chamber 21 from the first compartment 311 located on the side surface 212 and the bottom surface 211, and the gas 42 in the space in the molding chamber 21 is
And, it is suctioned under reduced pressure from the bottom surface 211 to the second compartment 312 (FIG. 2A). On the other hand, the steam 41 in the second heating step
Is the reverse of the flow of the first heating step (FIG. 2).
(B)). Next, steam 41 is supplied to all the compartments 31 as a main heating step.

After the completion of the first heating step, suction was performed from all the compartments 31 under reduced pressure to reduce the pressure in the chamber to -0.5 kg.
/ Cm ² may be provided. on the other hand,
In the flat mold 28, at the same time as the above-mentioned heating foam molding step,
Steam is supplied to the chamber 30 to heat the mold forming surface,
Indirect heating for transmitting heat to the surface material 12 is performed. Thereafter, a water cooling step of spraying cooling water onto the concave mold 29 and the flat mold 28 is performed,
Finally, the following cooling step by vacuum suction is performed.

The first heating step is performed for 30 to 120 seconds,
The heating step is 30 to 120 seconds, and the main heating step is 30 to 60 seconds.
The foamed resin composite molded article 1 can be molded in 3 seconds to 5 seconds in the exhaust step, 3 to 15 seconds in the water cooling step, 3 to 10 seconds in the drain discharge step, and 60 to 300 seconds in the cooling step. The cooling step is a method of reducing the internal pressure of the chamber 3 and the molding chamber 21 to cool the chamber 3 and the interior of the molding chamber 21 using the latent heat of evaporation of water.

Examples of actually molded foamed resin composite molded articles will be described below as Examples 2 to 4. Example 2 In this example, a panel molded body having the shape shown in FIG. 6 was molded as a foamed resin composite molded body. The molded panel is used as a heat insulating panel for building or the like. In molding, a molding machine as shown in FIG. 10 was used. The surface material, the back surface material, and the reinforcing material are 150 g / m ^{2 of} an organic solvent-based adhesive (manufactured by Konishi Bond: trade name: Bond G10), which has been lightly diluted with a thinner (thinner) twice and thinly brushed easily. It was applied and dried outdoors for 30 minutes.

The dimensions of the molded panel were 910 × 1820.
× 80 mm. A plywood having a vent hole serving as a back material of the panel molded body was disposed on the concave bottom surface. The plywood used was a commercially available decorative plywood having a thickness of 9 mm. The vent holes are 50 mm in diameter, 260 mm pitch in the longitudinal direction 50 mm inward from the edge of the plywood, and 230 mm in the width direction.
Provided on the pitch.

Next, a molded article of expanded polystyrene (size: 60
After placing plywood as a surface material by placing blocks of × 60 × 62 hmm) evenly in eight places and clamping the mold, the inside of the chamber is depressurized (-0.8 kg / cm ² ), and the filling gun is opened to expand the foamed resin particles. The filling was performed until the pressure in the chamber became 0 kg / cm ² .

Next, the inside of the chamber is again
The process of reducing the pressure to g / cm ² and filling the foamed resin particles again was repeated 5 times in total. Next, the first heating step and the second heating step are each performed for 60 seconds, and the main heating step is performed for 50 seconds.
After performing the evacuation for 3 seconds, the water cooling process for 5 seconds, the drainage for 10 seconds, and the cooling process for 180 seconds, the molded panel was released with a release pin and taken out.

The obtained molded panel was obtained without warpage and with good adhesive strength. The moisture content of the plywood is about 10-1
It was dried at room temperature at 2 wt%. After drying, the plywood did not peel off and there was no change in thickness. The weight of the molded panel is 2
The weight was 2 kg / piece and it was light enough to be carried by one person.

Example 3 The same molding machine as in Example 2 was used to mold a panel molded body having the shape shown in FIG.
The difference from the first embodiment is that the reinforcing material of the panel molded body is arranged at the center of the panel molded body over the entire thickness and is joined to the front plate and the back plate.

As the above-mentioned reinforcing material, Tsuga material 38 × 62 × 18
20 mm was used. In addition, ventilation holes having a diameter of 50 mm were provided at a pitch similar to that of Example 1 by separating the ventilation holes of the back plate by approximately 20 mm from both ends of the reinforcing material. The removed panel molded product was as good as in Example 1.

Embodiment 4 This embodiment is a panel molded body having the shape shown in FIG. 8, in which the reinforcing material is disposed at the small edge surface and the center at both ends in the width direction of the panel molded body. The ventilation holes in the back plate were provided 20 mm inward from the ends of the reinforcing members disposed on both the small edge surfaces. The front plate, the back plate, and the reinforcing material were coated with an adhesive, dried, and then nailed on the front and back, and placed in a concave mold.

Further, since there is no supply of steam from the fore face at both ends in the width direction, the first heating step and the second heating step were each performed for 90 seconds, and the main heating step was performed for 60 seconds. Otherwise, molding was performed under the same molding conditions as in Examples 1 and 2. The removed panel molded product was as good as in Examples 2 and 3.

Embodiment 5 This embodiment is a panel molded body having the shape shown in FIG. 9, in which a reinforcing material is disposed on the small edge surface and the center of the entire periphery of the panel. The ventilation holes in the back plate were provided 20 mm inside from the ends of the reinforcing members arranged on both small-mouthed surfaces, and the number of ventilation holes was increased by four compared to Example 3. Others are the same as the fourth embodiment. The panel molded body taken out is Example 2.
As good as in Nos. 4 to 4.

[0075]

As described above, according to the present invention, a foamed resin composite molding in which foamed resin particles are uniformly foamed and the foamed resin particles are firmly fused together, and the foamed resin body and the surface material and the back surface material are firmly fused. It is possible to provide a method for molding a body and a foamed resin composite molded article obtained by the method.

[Brief description of the drawings]

1A and 1B are explanatory diagrams of a molding method of a foamed resin composite molded article according to a first embodiment, and FIG. 1B is a cross-sectional view of the foamed resin composite molded article.

FIG. 2 is an explanatory view of (A) a first heating step and (B) a second heating step of a heat foam molding step in the first embodiment.

3A is a front perspective view of a foamed resin composite molded article according to Embodiment 1, and FIG. 3B is a rear perspective view of the same.

4A is a sectional view taken along line AA of FIG. 3A,
(B) is a sectional view taken along line BB, and (C) is a sectional view taken along line CC.

FIG. 5 is an explanatory diagram of a communication hole and its function in the first embodiment.

6A is a back view of a foamed resin composite molded article, and FIG. 6B is a cross-sectional view taken along line DD of FIG.

7A is a back view of a foamed resin composite molded article, and FIG. 7B is a cross-sectional view taken along line EE of FIG.

FIG. 8A is a back view of the foamed resin composite molded article, and FIG. 8B is a cross-sectional view taken along line FF of FIG.

9A is a back view of a foamed resin composite molded article, and FIG. 9B is a cross-sectional view taken along line GG of FIG.

FIG. 10 is a side view of the molding machine according to the first embodiment.

FIG. 11 is an explanatory diagram of an arrangement of a mold release pin and a filling gun in the first embodiment.

[Explanation of symbols]

 1. . . 10. a foamed resin composite molded article; . . 11. a foamed resin body; . . Surface material, 13. . . Backing material, 131. . . Vents, 14. . . 14. reinforcing material, . . Small face, 2. . . Mold, 21. . . Molding chamber, 22. . . 2. foaming space, . . Chamber, 31. . . Branch room, 311. . . First branch, 312. . . Second branch, 319. . . Communication hole, 41. . . Steam, 42. . . Gas in space,

 ──────────────────────────────────────────────────の Continued on the front page F-term (reference) 4F100 AB01B AB01C AB01D AE01B AE01C AK01A AK01B AK01C AK01D AK04A AK07A AK12A AP00D AS00B AS00C BA03 BA04 BA07 BA10B BA10C DH00D DJ05A GB03 AD03 A03 AD03 AD03 CB13 CN01 CN12 4F212 AA04 AA11 AA13 AD02 AD03 AD05 AD06 AD23 AG01 AG03 AG20 UA01 UB01 UB13 UB22 UL01 UL03

Claims (8)

[Claims] 1. A method of molding a foamed resin composite molded body comprising a foamed resin body and a front surface material and a back surface material integrally joined to front and back surfaces of the foamed resin body using a mold. In the molding method, a back material having a plurality of ventilation holes for supplying and exhausting steam is disposed on a bottom surface of the molding chamber of the mold, and a surface material is provided on an upper surface of the molding chamber. And a preparatory step of introducing foamed resin particles into the foamed space formed by the two, and supplying steam to the foamed space from one or a plurality of the vents, A heating foam molding step of performing heating foam molding of the foamed resin particles by exhausting air from the pores. 2. The molding machine according to claim 1, wherein the mold has a chamber disposed partially or entirely around the molding chamber, and at least a plurality of chambers disposed on the bottom surface of the molding chamber are provided. , And each of the compartments has a communication hole communicating with the molding chamber, and each of the compartments is connected to a steam supply pipe and an exhaust pipe. From one or a plurality of predetermined first compartments among the plurality of compartments, steam is supplied to the foaming space portion in the molding chamber through the communication holes and the vent holes provided in the back surface material, and other than the first compartments. A first heating step of discharging gas in the space of the foaming space from the second compartment through the communication hole and the ventilation hole, and, contrary to the first heating step, steam is supplied from the second compartment. ,on the other hand And a second heating step of discharging gas in the space from the first compartment. 3. The method according to claim 2, wherein the first compartment and the second
A method for molding a foamed resin composite molded article, wherein the compartments are alternately arranged. 4. The method for molding a foamed resin composite molded article according to claim 2, wherein the chamber for discharging the gas in the space in the heating foam molding step is suctioned under reduced pressure. 5. A foamed resin composite molded article comprising a foamed resin body, and a surface material and a backside material integrally joined to the front and back surfaces of the foamed resin body, wherein the backside material is A foamed resin composite molded article having vent holes for supplying and exhausting steam during molding of the foamed resin composite molded article. 6. The foamed resin composite molded article according to claim 5, wherein a reinforcing material is provided between the front surface material and the back surface material. 7. The foamed resin composite molded article according to claim 5, wherein the reinforcing material is disposed over the entire thickness of the foamed resin body. 8. The method according to claim 5, wherein
The foamed resin composite molded product, wherein the reinforcing material is provided at a small edge surface and a center in a width direction of the entire periphery of the foamed resin composite molded product.